Cross member having a hybrid structure

ABSTRACT

The invention relates to a cross member for a vehicle, said cross member comprising a reinforced base body ( 2, 2   b   , 2   c ) containing at least one air duct ( 14 ) and being embodied in an at least partially widened manner and as part of a housing ( 11 ) of a heating and/or air conditioning installation ( 12 ). Said air duct ( 14 ) of the base body ( 2 ) is connected to an air outlet ( 15 ) of the heating and/or air conditioning installation ( 12 ).

The invention relates to a crossmember having a hybrid structure for avehicle, in particular for arranging between A-pillars of a vehicle,comprising a basic body which is provided with a reinforcement and inwhich at least one air duct is arranged and which is furthermore atleast partially widened and is designed as part of a housing of aheating and/or air-conditioning system.

A crossmember of this type having a hybrid structure is disclosed, forexample, in DE 100 14 606 A1. In this case, in order to attachadditional functions, the crossmember is at least partially widened, atleast on one side, in particular in the central region, and is designedas part of a housing of a heating and/or air-conditioning system. Inaddition to a large construction space, this also gives rise to acomplex geometry for the crossmember, in particular a crossmember withan integrated air duct. The widened area results in a curved profile ofthe crossmember, in which a cover and a separate air duct are generallysubsequently required. Furthermore, the heating and/or air-conditioningsystem additionally has a branched air distribution device and istherefore heavy, since the flow ducts or air distribution ducts areusually formed from injection molded, hard, dimensionally stable shellsor blow-molded components. Due to complex geometries, the production ofrigid flow ducts of this type is particularly complicated andcost-intensive.

The invention is therefore based on the object of specifying acrossmember having a hybrid structure for a vehicle, which has aparticularly small construction volume.

According to the invention, the object is achieved by a crossmemberhaving a hybrid structure for a vehicle, comprising a basic body whichis provided with a reinforcement and in which at least one air duct isarranged and which is furthermore at least partially widened and isdesigned as part of a housing of a heating and/or air-conditioningsystem, with the air duct of the basic body being connected to an airoutlet of the heating and/or air-conditioning system.

The invention is based on the consideration that a crossmember for theintegration of functional elements, in particular in the form of asupporting element for a heating and/or air-conditioning system, is tobe simplified in such a manner that, in addition to thesupporting-element function, it also enables air to be fed directly toair exits with a complex, branched duct system being avoided. In thiscase, in addition to the simplification of the duct routing, the weightis also to be significantly reduced and a duct routing which isfavorable in terms of flow is to be made possible such that swirling ofthe fluid flowing through the flow duct is reliably avoided. For thispurpose, the crossmember serving as a supporting element for a heatingand/or air-conditioning system is firstly to be provided with an airduct which at suitable locations has openings via which the fluid, inparticular air, can emerge. Secondly, the air duct which is integratedin the crossmember is connected to an air outlet of the heating and/orair-conditioning system. This significantly reduces the number ofoutlets from a heating and/or air-conditioning system. An air duct whichis integrated in the crossmember and has a plurality of variable exitopenings fitted and its connection to the air outlet of the heatingand/or air-conditioning system make possible a particularly simple andstandardizable air distribution device which requires a particularlysmall amount of construction space. Owing to the simple construction andthe particularly variable adjustment of the exit openings, a resultantair distribution device can be adjusted and designed individually inaccordance with requirements, thus permitting particularly high thermalcomfort.

To arrange the crossmember and the course thereof in as individual amanner as possible, the basic body is expediently arranged in a mannersuch that it partially encircles the heating and/or air-conditioningsystem. For example, for this purpose the basic body is at leastpartially widened in one region in such a manner that it encircles theheating and/or air-conditioning system at the top, bottom, front and/orrear. For such great design freedom in the member profile, the basicbody comprises at least two subsections which are connected via a thirdsubsection forming a widened area. In other words: the basic body isexpediently divided into a plurality of subsections, with at least tworunning rectilinearly and uniformly and another running at leastpartially in a curved manner.

For an arrangement of the heating and/or air-conditioning system whichis as space-saving and construction-space-saving as possible, saidsystem is expediently arranged in the region of the third subsection onthe outer side thereof, with the two subsections being oriented at thesides of the heating and/or air-conditioning system in the form of sidearms. In this case, the side arms run substantially rectilinearly anduniformly whereas the third subsection runs in a curved manner in orderto accommodate the heating and/or air-conditioning system.

For feeding in air as simply as possible and for a particularly highpickup of the flow and with turbulence being avoided, the air outlet ofthe heating and/or air-conditioning system opens into the air duct ofone of the subsections forming a side arm. As an alternative or inaddition, the air outlet opens into the air duct arranged in the widenedregion of the basic body, i.e. in the third subsection, and/or runsthrough or crosses said duct. In a further alternative embodiment, thebasic body is at least partially formed from two ducts arranged parallelto each other. In this case, the air duct is expediently at leastpartially guided between the ducts arranged parallel to each other.

Depending on the type and design, the air duct is preferably formed inthe basic body. As an alternative or in addition, the air duct can beformed by a separate molded part. For a connection of the air duct tothe air outlet in a manner irrespective of constructional form, anadapter is expediently provided. For as variable as possible a designand configuration of the adapter element, the latter is advantageouslyformed from plastic.

The advantages obtained with the invention reside in particular in thefact that a crossmember which serves as a supporting element for aheating and/or air-conditioning system and has an integrated air ductconnected to an air outlet of the heating and/or air-conditioning systempermits great freedom in configuration and design in the member profile.In addition, such a multifunctional crossmember has a particularly lowconstruction volume and, owing to the air duct bringing about anadditional stiffening function, makes it possible for further holders tobe integrated on the crossmember. Furthermore, the crossmember has aparticularly lightweight structure with, at the same time, good crashabsorption and as good a vibration damping as possible.

Exemplary embodiments of the invention are explained in more detail withreference to a drawing, in which:

FIG. 1 diagrammatically depicts a basic body for a crossmember,

FIG. 2 diagrammatically depicts a hybrid member as shown in FIG. 1,

FIG. 3 diagrammatically depicts, in a perspective illustration, acrossmember with an integrated heating and/or air-conditioning system,

FIG. 4 diagrammatically depicts, in a perspective illustration, acrossmember with a heating and/or air-conditioning system connected toan air duct of the crossmember via an air outlet,

FIG. 5 diagrammatically depicts, in a perspective illustration, thecrossmember as shown in FIG. 3,

FIG. 6A to 6C diagrammatically depict an alternative embodiment for acrossmember with an integrated air duct and heating and/orair-conditioning system connected thereto, and

FIG. 7A to 7E diagrammatically depict an alternative embodiment for acrossmember with ducts arranged parallel to one another and an air ductarranged in between and a heating and/or air conditioning systemconnected to said duct.

Parts which correspond to one another are provided with the samereference numbers in all of the figures.

FIGS. 1 and 2 show a crossmember 1 having a hybrid structure for avehicle, which, for the connection of functional elements, such as, forexample, the instrument panel or airbags, is arranged between theA-pillars of the vehicle. The crossmember 1 has a basic body 2 which isformed from a bent sheet-metal part. The basic body 2 has an essentiallyU-shaped, slightly open profile, with the two open limb ends being bentoutward. The basic body 2 is widened in the central region 4, i.e. whenit is fitted into a vehicle in the region of the central console, thebasic body 2 is divided into two subsections 6, with each subsection 6likewise having a corresponding, essentially U-shaped, slightly openprofile. As an alternative, the basic body 2 may also be designed as ahollow profile with any desired cross section. In order to connectfunctional elements, such as, for example, airbags, knee impactprotection and/or in order to fasten an instrument panel, a plurality ofconnections 7 are provided on the basic body 2. Depending on the typeand design, the connections 7 are designed as bent sheet-metal partswhich are arranged in a form-fitting manner on the basic body 2 and arepermanently connected by means of a welding connection. However, theconnection may also take place by a different joining method. Theconnection 7 may also be formed in a hybrid structure, i.e. as aninjection-molded plastic part.

To increase the stability of the basic body 2, a reinforcement, alsocalled profiled core, of plastic is provided, in particular fitted, asillustrated in FIG. 2, essentially in the interior of the in particularU-shaped profile and has a honeycomb structure 10 formed from ribs 9.The honeycomb structure 10 is designed here in such a manner that theribs 9 are in each case arranged at an angle of approx. 45° to the sidewalls of the U-shaped profile of the basic body 2 and two ribs 9 meet inthe edge region. To increase the stability, the plastic may have glassfibers added. Depending on the type and design, such a stiffening ribstructure may also be provided in the connections 7 and may thereforebring about an increase in rigidity.

FIG. 3 shows an example of a connection of a housing 11 of a heatingand/or air-conditioning system 12 to the basic body 2. The housing 11 isgenerally formed from plastic and injection-molded on or fastened to thebasic body 2. As illustrated in FIG. 3, the basic body 2 at leastpartially encircles the heating and/or air-conditioning system 12.Depending on the arrangement of the heating and/or air-conditioningsystem 12 in the widened region 4, in particular in the central regionof the crossmember 1, the basic body 2 may run at the front, rear, aboveand/or below the heating and/or air-conditioning system 12. For thispurpose, the basic body 2 is divided into a plurality of subsections 2 ato 2 d, of which the subsections 2 a, 2 c form side arms of thecrossmember 1 which are connected to one another via the subsection 2 b,which forms the widened area and is therefore partially curved.Depending on the design of the basic body 2, the latter may be ofsingle-part or multipart design.

Flow ducts 13 branch off from the housing 11 of the heating and/orair-conditioning system 12.

For a particularly simple and space-saving construction of the basicbody 2 serving as a supporting element for the heating and/orair-conditioning system 12, an air duct 14 is integrated in it, asillustrated in FIG. 4. In this case, the air duct 14 additionally servesto stiffen the basic body 2 and is preferably formed from plastic.Depending on the type and design of the crossmember 1, the air duct 14may be injected as a plastic element or may be fitted in the basic body2 as a separate molded part.

In addition or as an alternative to the flow ducts 13 (FIG. 3), theheating and/or air-conditioning system 12 has at least one air outlet15. In this case, the air outlet 15 is connected to the air duct 14integrated in the subsection 2 a in order to laterally ventilate thevehicle interior via exits 16 fitted in the basic body 2. In order toventilate the front region, firstly a further air outlet 15 is providedwhich opens into the air duct 14 integrated in the subsection 2 b andruns through said duct. Secondly, a further flow duct 13 of the heatingand/or air-conditioning system 12 is provided, which flow duct directlyventilates the front region and crosses above or below the basic body 2,in particular the subsection 2 b thereof. Depending on the type andconstruction of the air outlet 15 or of the air duct 14, an adapterelement 17 may be provided to connect these components. In one preferredembodiment, the adapter 17 has (in a manner not illustratedspecifically) a blocking element, for example a flap, for controllingthe air flow. The adapter element 17 is preferably made from plastic andcan therefore be shaped in accordance with the cross section of the airoutlet 15 or of the air duct 14 to be connected. The adapter element 17is preferably integrally formed on the crossmember 1, in particular onthe basic body 2, and/or the air-conditioning system 12 (called HVAC forshort).

FIG. 5 illustrates an embodiment of the crossmember 1 in perspective. Inthis case, by way of example for the driver's side or left side of thecrossmember 1, i.e. for the subsection 2 a, an air feed into the airduct 14 integrated therein is illustrated. For this purpose, the airduct 14 is guided through the side wall of the basic body 2 at the endof the subsection 2 a designed as a side arm. The heating and/orair-conditioning system 12 is then, as shown in FIG. 4, connected fromthe rear to the basic body 2 in the widened region 4, with anassociated, lateral air outlet 15 then opening into the air duct 14 ofthe subsection 2 a.

FIGS. 6A to 6C show an alternative embodiment for the crossmember 1 witha heating and/or air-conditioning system 12 connected to the basic body2 from the rear, said system being arranged in the central region 4between two subsections 2 b, arranged parallel to each other, or arms ofthe basic body 2, and running through them. The connection of the airoutlet 15 of the heating and/or air-conditioning system 12 to the airduct 14 integrated in the basic body 2 is implemented by means of theadapter element 17. In this case, the adapter element 17 can be attachedfrom the outside in a particularly simple manner. FIG. 6C shows a basicbody 2 of this type in a perspective illustration.

FIGS. 7A to 7E show a further alternative embodiment for the crossmember1. In this case, the basic body 2 and the subsections 2 a to 2 c thereofare formed from two ducts 18 arranged parallel to each other. The ducts18 are also referred to as upper air flow and lower air flow. Betweenthe ducts 18, the air duct 14 is arranged in the region of the sidearms, i.e. in the region of the subsections 2 a, 2 c, of the basic body2. As illustrated in FIGS. 7D and 7E, the air duct 14 is connected inthe subsection 2 a and 2 c via the adapter element 17 to the air outlet15 of the heating and/or air-conditioning system 12.

LIST OF REFERENCE NUMBERS

-   1 Crossmember having a hybrid structure-   2 Basic body-   2 a to 2 d Subsections of the basic body-   4 Widened region of the basic body-   6 Subsections-   7 Connections-   8 Reinforcement-   9 Ribs-   10 Honeycomb structure-   11 Housing of the heating and/or air-conditioning system-   12 Heating and/or air-conditioning system-   13 Flow duct of the heating and/or air-conditioning system-   14 Air duct of the basic body-   15 Air outlet of the heating and/or air-conditioning system-   16 Exits-   17 Adapter element-   18 Ducts

1. A crossmember (1) having a hybrid structure for a vehicle, comprisinga basic body (2) which is provided with a reinforcement (8) and in whichat least one air duct (14) is arranged and which is at least partiallywidened and is designed as part of a housing (11) of a heating and/orair-conditioning system (12), characterized in that the air duct (14) ofthe basic body (2) is connected to an air outlet (15) of the heatingand/or air-conditioning system (12).
 2. The crossmember as claimed inclaim 1, characterized in that the basic body (2) is arranged in amanner such that it at least partially encircles the heating and/orair-conditioning system (12).
 3. The crossmember as claimed in claim 1,characterized in that the basic body (2) comprises at least twosubsections (2 a, 2 c) which are connected via a third subsection (2 b)forming a widened area.
 4. The crossmember as claimed in claim 3,characterized in that the heating and/or air-conditioning system (12) isarranged in the region of the third subsection (2 b) on the outsidethereof, the two subsections (2 a, 2 c) being oriented at the sides ofthe heating and/or air-conditioning system (12) in the form of sidearms.
 5. The crossmember as claimed in claim 4, characterized in thatthe air outlet (15) opens into the air duct (14) of one of thesubsections (2 a, 2 c) forming a side arm.
 6. The crossmember as claimedin claim 1, characterized in that the air outlet (15) opens into the airduct (14), which is arranged in the widened region (4) of the basic body(2), and/or runs through said duct.
 7. The crossmember as claimed inclaim 1, characterized in that the basic body (2) is at least partiallyformed from two ducts (18) arranged parallel to each other.
 8. Thecrossmember as claimed in claim 7, characterized in that the air duct(14) is at least partially guided between the ducts (18) arrangedparallel to each other.
 9. The crossmember as claimed in claim 1,characterized in that the air duct (14) is formed in the basic body (2).10. The crossmember as claimed in claim 1, characterized in that the airduct (14) is formed by a separate molded part.
 11. The crossmember asclaimed in claim 1, characterized in that an adapter element (17) isprovided for connecting the air duct (14) to the air outlet (15). 12.The crossmember as claimed in claim 11, characterized in that theadapter element (17) is formed from plastic.
 13. The crossmember asclaimed in claim 11, characterized in that the adapter element (17) isintegrated onto the air-conditioning system (12) and/or onto the airduct (14).